Hard alloys



Patented Feb. 22, 1949 HARD ALLOYS Roy B. McCauley, Chicago Heights, 111;

No Drawing.

Application April 19, 1945,

Serial No. 589,270

8 Claims.

This invention relates to hard ferrous phosphide alloys characterized by high abrasion resistance as well. as corrosion resistance.

Thisapplication is a continuation-in-part of my application Serial No. 476,967, filed February 24, 1943, now abandoned.

In my earlier patents, No. 2,261,174, issued November 4, 1941, No. 2,194,982, issued March 26, 1940, and No. 2,117,191, issued May 10, 1938, I have disclosed iron-phosphorus alloys which are highly acid resistant when further alloyed with various acid resistant metals such as chromium, nickel and copper in substantial portion internary and higher alloys together with other metals for specific modifying effects. The phosphorus content thereof varied considerably but the quantity of the acid corrosion resisting metals was necessarily high for this purpose.

I have discovered that iron phosphorus alloys of the type generally contemplated in my earlier patents, can be produced at low cost by the use of, small amounts of alloying ingredients such as copper and nickel, to impart to the alloy properties which adapt the same to entirely difierent applications. Such a change in the properties of the alloys, when the range of alloying ingredients of copper and nickel are carried beyond the ranges contemplated in my earlier disclosures, were not obvious from the developments disclosed in those patents and constitute an independent inventive conception. The essential alloying ingredients within the ranges in accordance with the present invention bestow upon the alloy a high inherent resistance to abrasion and to corrosion to non-oxidizing acids such as hydrochloric and sulfuric acid, together with extreme hardness and exceptional toughness. The alloys contemplated herein, having a reduced content of corrosion resistance alloying metals as well as phosphorus from that mentioned in my earlier patents, possesses enhanced utility in the field of welding rod, strip or powder, for various fusionprocesses. Also, the alloysin accordance withthe present invention are extremely useful for valve seats and gates, sand conditioning parts andfor the handling of abrasives in acid solutions.

In accordance with the present invention, very little chromium is used as contrasted to my earlier patents, and is reduced to such small quantity as may necessarily be picked up in scrap metal when used as a source of metal or from the furnaces wherein chromium alloys have been melted, and is present in quantity of less than one percent. Similarly the copper and nickel are used in minor quantity, only sufficient to impart corrosion resistance, disembrittlement and hardness,..

ranging from 0.50% to 6.00%, and preferably, be.-

lowthis upperlimit, which is the desirable range for complementing the desirable low fusing .quality of the phosphorus, and the phosphorus likewise is reduced to the lower. quantity of the order of 1.00% to 8.00%.

Such alloy has a Rockwell C scale of hard ness of to combined with such strength,

toughness and ready fusibility and alloyability as to be applicable in the forms mentioned by fusion.

in such situations as valve seats and gates, sand conditioning parts, armor plate, and for handling It will be apparent that the complex .alloy of the present invention comprises a low'phosphorus-iron alloy containing a small quantity of copper, nickel and with traces, if any, of chromium, with silicon and/or manganese being.- present as impurities according to the following:

general formula:

Per cent Copper 0.50 to 6.00 Nickel 0.50 to 6.00 Phosphorus 1.00 to 8.00 Chromium 0.00fto 1.00

Iron balance of 100.00 parts.

In a more specific mode of execution of the invention, the nickel and copper content may be present in quantities of about 5.00% with or without a chromium content up to 1.00%. A hardness of 65 C Rockwell can be produced from any phosphorus content ranging from 1.00% to less than 8.00 This alloy is highly resistant to solutions such as hydrochloric and sulfuric acids and their chlorides and sulfates.

The alloys in accordance with the instant'invent-ion can be produced with maximum hard-1 ness at the lowest possible phosphide alloy cost, with better grinding properties and greater physical strength by using a lower phosphorus limit of about 1.00% with about 5.00% copper and.

5.00% nickel. Where greater resistance to corrosion is necessary, the phosphorus content is increased from 1.00% as needed up to about 8.00%, without altering the hardness of the alloy, but with some increase in cost and decrease in physical properties. Any appreciable variation in the nickel and/ or copper content also alters the hardness and corrosion resistance of the alloy so that within certain limits these properties can be adjusted. Thus, alloys adapted to different types of applications may be produced in dependence upon specific needs, for example, for the purpose of resisting certain types of corrosion, to obtain increased strength, to render the alloy capable of being ground easily by inexperienced help, to decrease the cost, or to attain a plurality of these objectives.

The following two specific formulas coming within the above-recited general formula will serve to identify the invention more exactly:

Formula 1 Per cent Copper 4.98 Nickel 5.25 Phosphorus 1.82 Chromium 0.53

Iron, balance 100.00.

A hard abrasion-resisting tough and strong alloy of this analysis will afford a Rockwell C scale test of around 65. There will be no soft specimens produced. Even with low copper and nickel, to-wit, around .50, R/C will still be high. The specimens will be found to embody conditions adapting the alloy to serve as armor plate.

Formula 2 Per cent Copper 4.85 Nickel 5.15

Phosphorus 6.20 Chromium 0.24

Iron, balance 100.00.

This hard abrasion and corrosion resistant, tough and strong alloy will meet a R/ C test of 65 to '70 and can be produced in the form of welding rod, strip metal, powder, etc., to be united by any of the known methods of fusion as a protective coating on existing metal objects. The relatively high phosphorus content with respect to that in Formula '1, imparts fluidity to the alloy at low temperatures and acts to enhance its alloying ability at such low temperature and thereby to prevent its oxidation at fusing temperatures. An oxide is produced while welding which is more fluid than the aloy at the welding temperature and acts as a flux for the surface to be welded, preventing it from oxidizing at the temperature of the welding flame and making it unnecessary to use any other fluxes.

While the specific formulas above have disclosed the use of phosphorus in amounts of 1.82% and 6.20%, any amount intermediate these quantities and below 8.00% of the alloy may be used. By adding more and more phosphorus from the the lower value to the upper value the alloy is rendered more fluid at a given temperature, in dependence upon the specific material being worked on.

I claim:

1. A stable, inherently hard abrasive-resistant tough alloy comprising copper about 4.85%; nickel about 5.15%; phosphorus about 6.20% and iron containing less than 1.00% of chromium, silicon and other non-essential ingredients of commercial grades of scrap iron.

2. A stable, inherently hard abrasive-resistant and tough alloy comprising copper about 4.98%; nickel about 5.25%; phosphorus about 1.82%; and the remainder substantially all iron containing less than 1.00% of chromium, silicon and other non-essential ingredients of commercial grades of scrap iron.

3. A hard, tough, abrasion and corrosion resistant phosphorus-iron alloy having alloying materials in proportions adjusted to enhance fusion application comprising an iron alloy having 1.00% to 8.00% of phosphorus, less than 6.00% of both copper and nickel ranging to a lower limit of 0.50% of each, the remainder being substantially all iron with less than 1.00% of chromium, silicon or manganese acting as impurities in the alloy.

4. Fusion applicable, hard, abrasion and corrosion resistant ferrous alloy comprising about 4.85% 'copper, 5.15% nickel, and 6.20% phosphorus, with any traces of chromium, silicon or manganese therein acting as impurities in the alloy.

5. Fusion applicable, hard abrasion and corrosion resistant ferrous alloy comprising about 4.98% copper, 5.25% nickel and 1.82% phosphorus, with the remainder substantially all iron with any traces of chromium, silicon or manganese therein actin as impurities in the alloy. I 6. A stable, inherently hard, corrosion resistant and abrasion resistant tough alloy containing copper of about 5%; nickel about 5%, and phosphorus about 1% to 8%, depending upon the degree of desired corrosion resistance, with the remainder substantially all iron with incidental impurities.

'7. A stable alloy having extreme inherent hardness, toughness, strength and resistance to abrasion; said alloy containing about 1.00% to 8.00% phosphorus, less than 5.00% copper ranging to a lower limit of 0.50% thereof, less than 6.00%

nickel ranging to a lower limit of 0.50% thereof, and the remainder substantially all iron.

8. A stable alloy having extreme inherent hardness, toughness, strength and resistance to abrasion; said alloy containin less than 5.00% copper ranging to a lower limit of 0.50% thereof; about 0.50% to 5.00% nickel; from 1.00% to less than 8.00% phosphorus; and the remainder substantially all iron.

ROY B. MCCAULEY.

REFERENCES CITED The following references are of record in the file of this patent:

UNITED STATES PATENTS Number Name Date 2,194,982 McCauley Mar. 26, 1940 2,215,740 Lorig Sept. 24, 1940 2,261,174 McCauley Nov. 4, 1941 2,289,365 Jerabek July 14, 1942 FOREIGN PATENTS Number Country Date 365,538 Great Britain Jan. 18, 1932 

